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:crazyeyes:
 
My suggestion would be basically what you've gotten before : cut/grind/file the head off and remove the pan. Very possibly the bolt will loosen up once the pan is off, and you can turn it out easily. If not, depending on what kind of access you have, I would probably either try to drill it out, or weld a nut to it.
Eg, https://weldingweb.com/showthread.php?t=31039
 
I hear you Randall, but if I leave the pan, on, what about the metal shavings. I could perhaps get in and weld, but I am afraid my welding would not penetrate enough to hold. This thing has kinda clean oil it and I was thinking about just replacing the filter until I get better positioning. I guess the best thing to do is test the compression with the dirty oil to see if it is even worth it.
Steve
 
As far as the welding, well, if using a cutoff wheel and re-shaping the hex to fit a slightly smaller six-point socket doesn't work, do NOT cut a slot in it for a screwdriver bit, or if it's that tight it will peel the edges right off.

If no joy, find a nut that will fit onto the remains of the pan bolt.
Tight enough it will take some tightening with a big wrench to get it onto the remains.
Then, arc-weld the nut to the plug on the INSIDE of the nut to the plug.
Sometimes, the act of heating will expand the metal plug into the corrosion in the aluminium pan and when cool will allow easier removal. Once cool, and you're satisfied with the weld, remove the nut and plug with a box-end or socket on breaker bar. Do Not use an impact unless your are darn certain your weld is certifiable, or you'll just break the weld.
 
Well I tried the stud extractor from Sears on an impact gun and it rounded and filed the head of bolt more. I think I am going to try and weld the nut on to the bolt like Randall and TOC suggested. I do not have an arc weld. I just have a good quality 110 volt wirer feed. Do you think that will do the job or do I need an arc welder. The link Randall supplied seems like they use arc welders.
Steve
 
Wire feed works
Penetration is what you want.
If an impact rounded it, you've got corrosion issues you haven't had nightmares about....yet.
Got a gas torch?
 
Yes TOC there is something going on here that is affecting my personal unconscious. Perhaps it is even the collective unconscious come to teach. I perhaps contributed to the impact tool failure and rounding out of the bolt head. The tool was designed for use with a hammer; the hammer blow combined with the reverse cutting in the tool head would bit and spin the bolt head. With my wisdom, I hooked the tool to my air gun and tried to hold it against the bolt. The problem there is I could not hold the tool tight enough and the tool turned in to a rotary file and rounded the head more. I perhaps would have been better off to use a hammer, but who knows I might have done more damage. I am good with a hammer, lots of carpentry. But yes it is really stuck. In the beginning, I did get some could bits with the vise grips, but no joy. I might weld the nut on or not, I need to step back for a minute. I ran the engine with the old oil and the old oil was not horrible. I do have another pan but it is on another car. Who knows, this whole situation could be serendipitous and the collective conscious is showing me to pull the pan and clean the screen. I have read that the oil pump screen on the 9000 can clog.
Steve
 
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